Air-Cooled Proton Exchange Membrane Fuel Cell Technologies

Air-cooled proton exchange membrane fuel cells (PEMFCs) integrate the cathode reactant stream with the thermal management system, eliminating the need for separate liquid coolants and heat exchangers. In an open-cathode design, ambient air is drawn directly across the catalyst layers to supply oxygen and remove heat, offering a lightweight and compact solution for portable power, unmanned aerial vehicles and standby applications. The absence of a liquid cooling loop reduces system complexity but introduces challenges in maintaining membrane hydration, ensuring uniform temperature distribution and preventing electrolyte dehydration under variable loads and environmental conditions. Recent research has targeted optimisation of flow-field geometries, advanced gas diffusion layer materials and operating strategies to balance efficient heat dissipation with high electrochemical performance. Innovations in graded hydrophobic additives and structured bipolar plates have enhanced water management and current density uniformity. System-level approaches—such as air recirculation, controlled stoichiometry and pressurised operation—have broadened the operational envelope across diverse climates. Collectively, these strides in modelling, material science and prototype testing are accelerating the translation of air-cooled PEMFCs into robust, sustainable power solutions.

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Air-Cooled Proton Exchange Membrane Fuel Cell Technologies publication trend

The graph below shows the total number of articles in air-cooled proton exchange membrane fuel cell technologies across all publications each year (not limited to Nature Index journals).

Technical terms

Proton Exchange Membrane Fuel Cell (PEMFC): A fuel cell that uses a polymer electrolyte membrane to conduct protons from the anode to the cathode while separating the reactant gases.

Open-Cathode Design: A configuration in which ambient air is directly drawn through the cathode channels for both oxidant supply and thermal management, without liquid cooling.

Gas Diffusion Layer (GDL): A porous medium that distributes reactant gases uniformly over the catalyst layer and facilitates water management and electron conduction.

Flow Field: The network of channels etched into the bipolar plate or flow plate that directs gas and cooling airflow across the cell surfaces.

Stoichiometric Flow Ratio: The ratio of actual airflow supplied to the theoretical minimum required to sustain the electrochemical reaction, often used to control temperature and hydration.

References

1. Application progress of small-scale proton exchange membrane fuel cell. Energy Reviews (2023).
2. Optimisation of air cooled, open-cathode fuel cells: Current of lowest resistance and electro-thermal performance mapping. Journal of Power Sources (2015).
3. Effects of Cathode Gas Diffusion Layer Configuration on the Performance of Open Cathode Air-Cooled Polymer Electrolyte Membrane Fuel Cell. Energies (2022).
4. Improving Water Management and Performance of an Air-Cooled Fuel Cell System Using Pressurized Air for Aviation Applications. Journal of The Electrochemical Society (2021).
5. Numerical Study on Effect of Flow Field Configuration on Air-Breathing Proton Exchange Membrane Fuel Stacks. Energies (2024).
6. A Thermodynamic Analysis of an Air-Cooled Proton Exchange Membrane Fuel Cell Operated in Different Climate Regions. Energies (2020).